The document discusses various Lean concepts including the 7 wastes (muda), sources of unevenness (mura), and going beyond one's capabilities (muri). It explains that muda refers to any non-value adding activities that burden the production system and increase costs. The 7 types of muda are transportation, inventory, motion, waiting, overproduction, overprocessing, and defects. Mura causes muda by creating an irregular production schedule and workload fluctuations. Muri occurs when operators or machines are overburdened and utilized over 100% of their capacity. Standardization, visual management, and preventative maintenance techniques can help address mura and muri. The document emphasizes eliminating the root causes of issues through asking "
6. โข MURI, overburden, can result from Mura, and
from removing too much Muda (waste) from the
process.
โข When operators or machines are utilized for more
than 100% to finish their task, they are
overburdened.
โข This means breakdowns when it comes to
machines and absenteeism when it comes to
employees.
โข To optimize the use of machines and make sure
they function properly, preventative- and
autonomous maintenance can be implemented.
โข To prevent overworked employees, safety should
be the focus of all process designs and all
standard work initiatives.
7. Types of Muri
People Related Muri
โข Using standard work
โข Using 6S
โข Using Jidoka Principles
Machines Related Muri
โข Preventive Maintenance
โข Autonomous Maintenance
8. Standardisation
โข Standardization or standardisation
is the process of implementing and
developing technical standards.
Standardization can help to
maximize compatibility,
interoperability, safety,
repeatability, or quality. It can also
facilitate commoditization of
formerly custom processes.
11. Machine related Muri
Preventive Maintenance
โข Preventative maintenance is
maintenance that is regularly
performed on a piece of
equipment to lessen the
likelihood of it failing.
โข It is performed while the
equipment is still working, so
that it does not break down
unexpectedly.
Autonomous Maintenance
โข Autonomous maintenance is
โindependentโ maintenance
carried out by the operators of the
machines rather than by dedicated
maintenance technicians.
โข Autonomous maintenance has the
operators performing the simpler
maintenance routines such as
lubrication, bolt tightening, cleaning
and also inspection and monitoring.
16. MURA IN WORK
โข Rushing type production model (evening production model, week-end
production model, month-end production model)
To eliminate production variation for weekly, daily or
hourly production quantity.
โข Allocation of manpower (capability) and the work involved (load) are not
balanced.
โข Unbalanced production capability among different processes.
โข Making too many in one go
To produce necessary quantity of necessary items at
necessary timing only.
โข Working is not rhythmical.
19. ECONOMIC COST OF WASTE
Every business activity absorbs resources and
every resource has a cost
Every waste has a cost, and that is direct loss to
the company.
Economic value of waste in a process industry
are in the range of 10 -35% of annual turnover
20. 7 FORMS OF MUDA
Unnecessary motions
Waiting for work and materials
Transportations
Over-production
Processing
Inventories/ Unnecessary W-I-P
Corrective operation
21. MUDA of Motion
Movement that does not add value
โข Searching for files
โข Extra clicks or key strokes
โข Clearing away files on the desk
โข Gathering information
โข Looking through manuals and
catalogs
โข Handling paperwork
22. MUDA of Waiting
Idle time created when material, information, people or
equipment is not ready.
Waiting for:
โข Faxes
โข The system to come back
โข Copier machine
โข Customer response
โข A handed off file to come back
23. MUDA of Transport
I am more expensive
since raw material is
coming from a far
off place.
24. MUDA of Transport
Movement of information that does not add value:
โข Carrying documents to and fro from shared
equipment
โข Taking files to another person
โข Going to get signatures
25. MUDA of Over
production
Generating more information than the customer needs right
now:
โข More information than the customer needs
โข Creating reports no one reads
โข Making extra copies
โข More information than the next process needs
26. MUDA of Process
1. Using more expensive
equipment or tools where
simpler ones would suffice.
2. Having meetings that are not
needed.
3. Having people at meetings
that are not required.
4. Agenda points, not to be
included;
27. MUDA of
Process
Efforts that create no value from the customer
viewpoint:
โข Creating reports
โข Repeated manual entry of data
โข Excessive paperwork
โข Duplicity of work
โข Use of outdated standard forms
โข Use of inappropriate software
28. More information, project, material on hand than the
customer needs right now:
โข Files waiting to be worked on
โข Open projects
โข Office supplies
โข E-mails waiting to be read
โข Unused records in the database
29. Work that contains errors, rework, mistakes or
lacks something necessary:
โข Data entry error
โข Pricing error
โข Missing information
โข Missed specifications
โข Lost records
โข Rework
โข Rescheduling meetings
30. Find the Root Cause
- Asking โWHYโ for 5 times
- 5W 1H
How to eliminate muda??
31. The Five Ws and The One H
Who What Where
1. Who does it?
2. Who is doing it?
3. Who should be doing it?
4. Who else can do it?
5. Who else should do it?
6. Who is doing 3-Mus?
1. What to do?
2. What is being done?
3. What should be done?
4. What else can be done?
5. What else should be done?
6. What 3-MUs are being
done?
1. Where to do it?
2. Where is it done?
3. Where should it be done?
4. Where else can it be done?
5. Where else should it be
done ?
6. Where are 3- MU s being
done?
5 W 1 H of MUDA